Wetsuit and associated method of manufacture

ABSTRACT

A wetsuit having a torso, arms and legs has an outer layer extending over the torso, the arms and the legs, the outer layer having a substantially uniform thickness throughout the torso, the arms and the legs. Plural ancillary panels are attached to the outer layer along an inner surface thereof.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 60/816,144 filed Jun. 23, 2006.

BACKGROUND OF THE INVENTION

This invention relates to wetsuits. This invention also relates to an associated method of manufacture.

Wetsuits are made of water resistant material such as neoprene. Typically, if not universally, the neoprene has two thicknesses, a thinner thickness of about 2 mm for the arms and at least the knee regions of the legs and a thicker thickness that extends over the anterior and posterior sides of the torso and the anterior and posterior sides of the thighs. The different panels of the thin and thick neoprene material are first glued to one another along their edges and then stitched or sewn together along their inner surfaces.

This structure and method of manufacture can give rise to undesired stiffness and internal stresses that detract from the wearer's performance in such sports as triathlon contests.

SUMMARY OF THE INVENTION

The present invention aims to provide an improved wetsuit, particularly a wetsuit where stiffness and internal stresses are reduced. Concomitantly, the present invention aims to provide a wetsuit wherein sports performance is enhanced relative to existing wetsuit construction. The present invention aims to provide a related method of manufacture that facilitates wetsuit improvement.

A wetsuit having a torso, arms and legs comprises, in accordance with the present invention, an outer layer extending over the torso, the arms and the legs, the outer layer having a substantially uniform thickness throughout the torso, the arms and the legs. Multiple ancillary panels are attached to the outer layer along an inner surface thereof.

The outer layer is preferably made of a plurality of outer panels joined to one another along watertight seams, the outer panels each having the substantially uniform thickness.

The ancillary panels are preferably made of a foam material. The ancillary panels are preferably bonded or adhesively adhered to the inner surface of the outer layer. This adhesive attachment may be effectuated via a two-sided adhesive material. In addition, the ancillary panels may be sewn in blind stitches along respective edges to the inner surface of the outer layer.

The outer layer extends over a vast majority of the torso, the arms and the legs. Accordingly, there may be areas of relatively small area that are covered with a different material. For instance, the inner sides of the forearms may incorporate a friction enhancing material.

In one embodiment of the invention, the outer layer has a thickness of approximately 2 mm throughout, while the ancillary layers each have a substantially uniform thickness of less than about 3 mm throughout. However, it is to be noted that the outer layer and the ancillary layers may have different thicknesses. For triathlon competition, the combined thickness must be less than 5 mm. Accordingly, the outer layer may have a thickness of 1 mm and the ancillary layers or panels a thickness of 4 mm. Alternatively, the outer layer and the ancillary layers or panels may be each 2 mm thick, for a combined thickness of 4 mm.

Where the torso, the arms and the legs each have a longitudinal axis, the ancillary panels may include a first plurality of panels disposed in one of the torso, the arms and the legs. The panels of the first plurality of panels are spaced from one another along at least one elongate gap extending substantially parallel to the respective longitudinal axis of the one of the torso, the arms and the legs. The ancillary panels may further include a second plurality of panels disposed in another one of the torso, the arms and the legs, the panels of the second plurality of panels being spaced from one another along at least one elongate gap extending substantially parallel to the respective longitudinal axis of the other one of the torso, the arms and the legs.

The ancillary panels may include a plurality of chest panels disposed on an anterior side of the torso and spaced from one another along an elongate gap extending substantially parallel to an axis extending from a neck region to a crotch region on the anterior side of the torso.

The ancillary panels may include a plurality of abdominal panels disposed on an anterior side of the torso and spaced from one another along an elongate gap extending substantially parallel to an axis extending from a neck region to a crotch region on the anterior side of the torso.

The ancillary panels may include a plurality of thigh panels disposed on one of the legs and spaced from one another along an elongate gap extending substantially parallel to an axis extending from a crotch region at an upper end of the thigh to a knee region at a lower end of the thigh.

The ancillary panels may include a plurality of calf panels disposed on one of the legs and spaced from one another along an elongate gap extending substantially parallel to an axis extending from a knee region to an ankle region of the leg.

In a specific embodiment of the invention, the ancillary panels include a first plurality of panels disposed in a chest area of the torso, a second plurality of panels disposed in a back area of the torso, a third plurality of panels disposed in an abdominal region of the torso, a fourth plurality of panels disposed in each thigh region of the legs, and a fifth plurality of panels disposed in a calf region of each leg.

A method of making a wetsuit comprises, in accordance with the present invention, (a) cutting a plurality of outer panels from waterproof sheet material, the outer panels having the same substantially uniform thickness, (b) attaching the outer panels to one another to form a continuous outer layer having a torso, arms and legs with the substantially uniform thickness throughout, (c) cutting a plurality of ancillary panels from foam sheet material, and (d) attaching the ancillary panels to selected ones of the outer panels along inner surfaces thereof.

Where the torso, the arms and the legs each have a longitudinal axis, the attaching of the ancillary panels includes (i) attaching a first plurality of ancillary panels to outer panels of one of the torso, the arms and the legs so that the panels of the first plurality of ancillary panels are spaced from one another along at least one elongate gap extending substantially parallel to the respective longitudinal axis of the one of the torso, the arms and the legs, and (ii) attaching a second plurality of ancillary panels to outer panels of another one of the torso, the arms and the legs so that the panels of the second plurality of ancillary panels are spaced from one another along at least one elongate gap extending substantially parallel to the respective longitudinal axis of the another one of the torso, the arms and the legs.

The attaching of the ancillary panels may include bonding or adhesively adhering the ancillary panels to the inner surface of the outer panels. Two-sided adhesive sheet material may be cut into shapes congruent with the different ancillary panels. The attaching of the ancillary panels may also include sewing the ancillary panels via blind stitches along respective edges to the inner surfaces of the outer layer and particularly of the outer panels.

A wetsuit in accordance with the present invention has improved performance characteristics, while conforming to triathlon rules pertaining to wetsuit construction and specifications. The disposition of gaps between adjacent ancillary panels along longitudinal directions results in corresponding channels along the outer surface of the wetsuit, which provide paths for water flow and thereby reduce drag. The multiple parallel panel construction in the chest the wetsuit also serves to reduce constrictive pressure on lung expansion, while the multiple panel construction in the thigh and calf regions serves to reduce constrictive pressure on muscle contraction.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a wetsuit, on a female form, in accordance with the present invention.

FIG. 2 is a rear elevational view of a wetsuit, on a male form, in accordance with the present invention. The wetsuit may have different dimensions appropriate for male and female forms, but the components, structure, and manner of manufacture are the same.

FIG. 3 is a view similar to FIG. 1 showing patterns or panels of an outer layer of the wetsuit of FIGS. 1 and 2.

FIG. 4 is a schematic partial perspective view, partially broken away, showing a layer structure of the wetsuit of FIGS. 1-3.

DETAILED DESCRIPTION

As shown in FIGS. 1 and 2, a wetsuit 10 has a torso 12, arms 14 and 16 and legs 18 and 20. A zipper 22 extends along a posterior or back side of the torso 12, as shown in FIG. 2. Wetsuit 10 comprises a continuous, but not necessarily unitary, outer layer 24 extending over torso 12, arms 14 and 16 and legs 18 and 20. Outer layer 24 has a substantially uniform thickness of approximately 2 mm throughout torso 12, arms 14 and 16 and legs 18 and 20. Outer layer 24 is made of a water-resistant or -impervious material such as neoprene cut from sheets into patterns or panels 23 (FIG. 3) that are connected to each other along abutting edges by glue and by blind stitching along an inner surface 30 (FIG. 4) to form watertight seams 25, as shown in FIG. 3.

As depicted in FIG. 1, wetsuit 10 further comprises a pair of ancillary chest panels 26 and 28 attached to inner surface 30 of outer layer 24 on an anterior side (not separately designated) of torso 12. Chest panels 26 and 28 are spaced from one another by and along an elongate gap 32 extending substantially parallel to a longitudinal axis or midline 34 extending from a neck region 36 to a crotch region 38 on the anterior side of the torso. A plurality of ancillary abdominal panels 40 and 42 are disposed on inner surface 30 of outer layer 24 on the anterior side of torso 12 and spaced from one another along an elongate gap 44 extending substantially parallel to axis or midline 34. Owing to the resilience of outer layer 24 and the increased thickness of the wetsuit in the areas of the ancillary panels (e.g., panels 26, 28, 40, 42), gaps 32 and 44 underlie respective channels or grooves (not separately designated) formed along the outer surface of the wetsuit 10.

As further depicted in FIG. 1, wetsuit 10 further comprises (a) a first pair of ancillary thigh panels 46 and 48 disposed along inner surface 30 of outer layer 24 on leg 18 and (b) a pair of ancillary thigh panels 50 and 52 disposed along inner surface 30 of outer layer 24 on leg 10. Thigh panels 46 and 48 are spaced from one another along an elongate gap 54, while thigh panels 50 and 52 are spaced from one another along a mirror-image gap 56. Generally, the left and rights sides of wetsuit 10 are mirror images of one another.

FIG. 1 also depicts a pair of angled knee panels 58 and 60 on leg 18 and approximately oppositely angled knee panels 62 and 64 on leg 20. Panels 58 and 60 are spaced from one another by an elongate gap 66, while panels 62 and 64 are spaced from one another by an elongate gap 68.

As illustrated in FIG. 2, wetsuit 10 is provided on inner surface 30 of outer layer 24 with two long back panels 70 and 72 and two short, slightly boomerang-shaped back panels 74 and 76. Panels 70 and 74 are located on one side of zipper 22, while panels 72 and 76 are located on the opposite side of the zipper. Panels 70 and 74 are spaced from one another by a narrow gap 78, and panels 72 and 76 are separated from one another by another narrow gap 80.

As additionally illustrated in FIG. 2, wetsuit 10 additionally incorporates two gluteus panels 82 and 84, a first two ancillary thigh panels 86 and 88 and a second two ancillary thigh panels 90 and 92, all attached to inner surface 30 of outer layer 24. Thigh panels 86 and 88 are disposed in the thigh area (not designated) of leg 20, while thigh panels 90 and 92 are disposed in the thigh region of leg 18. Thigh panels 86 and 88 are spaced from one another along an elongate gap 94 extending longitudinally along leg 20. Analogously, thigh panels 90 and 92 are spaced from one another along an elongate gap 100 extending longitudinally along leg 18.

FIG. 2 further shows two posterior calf panels 106 and 108 disposed on a back side of leg 20 and another two posterior calf panels 110 and 112 disposed on a back side of leg 18. Calf panels 106 and 108 are spaced from one another along an elongate gap 114 extending longitudinally along the lower portion (not separately designated) of leg 20, i.e., substantially parallel to a longitudinal axis or midline 116 itself extending from a knee region 98 to an ankle region 118. Calf panels 110 and 112 are spaced from one another along an elongate gap 120 extending longitudinally along the lower portion (not separately designated) of leg 18, i.e., substantially parallel to a longitudinal axis or midline 122 itself extending from a knee region 104 to an ankle region 124.

FIG. 1 shows two anterior leg panels 126 and 128 disposed on a front lower side of leg 20. Leg 18 also has two anterior leg panels 130 (only one visible). Leg panels 126 and 128 are spaced from one another along an elongate gap 132 extending longitudinally along the lower part of leg 20, i.e., substantially parallel to a longitudinal axis or midline 131 itself extending from knee region 98 to an ankle region 118. Calf panels 130 are spaced from one another along an elongate gap 133 extending longitudinally along the lower portion (not separately designated) of leg 18.

As indicated above, outer layer 24 is made of multiple outer panels 23 of neoprene material joined to one another along watertight seams 25, the outer panels each having the substantially uniform thickness of approximately 2 mm.

The ancillary panels disposed along inner surface 30 of outer layer 24, including chest panels 26 and 28, abdominal panels 40 and 42, thigh panels 46, 48, 50, 52, 86, 88, 90, and 92, back panels 70, 72, 74, and 76 and calf or leg panels 86, 88, 90, 92, 126, 128, and 130, are preferably made of a foam material having a uniform or common thickness no greater than approximately 3 mm. The ancillary panels are preferably bonded or adhesively adhered to inner surface 30 of outer layer 24. This adhesive attachment may be effectuated via a two-sided adhesive sheet material 134, illustratively shown in FIG. 4 with respect to chest panel 26. In addition, the various ancillary panels may be sewn in blind stitches 136 along respective edges 138 to inner surface 30 of outer layer 24. Preferably, the ancillary panels fall within respective panels 23 of outer layer 24, so that none of the ancillary panels overlaps any seam 25 of outer layer 24.

Outer layer 24 extends over a vast majority of torso 12, arms 14 and 16 and legs 18 and 20. Outer layer 24 may include sections 140 and 142 (FIG. 3) of relatively small area that are covered with a different material. The inner sides of the forearm region of arms 14 and 16 may be formed by panels 144, 146 of a friction enhancing material (FIG. 3).

In making wetsuit 10, one cuts a plurality of panels 23 from waterproof sheet neoprene material and attaches the panels to one another along abutment seams 25 to form continuous outer layer 24 with the shapes of torso 12, arms 14 and 16 and legs 18 and 20. This attachment is effectuated via adhesive and blind stitching (e.g., a blind chain stitch). The ancillary panels including chest panels 26 and 28, abdominal panels 40 and 42, thigh panels 46, 48, 50, 52, 86, 88, 90, and 92, back panels 70, 72, 74, and 76 and calf or leg panels 86, 88, 90, 92, 126, 128, and 130, are cut from foam sheet material and adhesively attached via congruently cut double-sided adhesive sheets 134 to inner surface 30 of outer layer 24. In addition, the ancillary panels are sewn along their respective edges via blind stitching to the inner surface 30 of outer layer 24. Typically, the ancillary panels are attached to outer layer 24 prior to the complete formation of the outer layer. For instance, the ancillary panels may be bonded and sewn first to respective outer panels 23, before the outer panels 23 are joined to each other. Subsequently, one joins the outer panels 23 to one another along their edges to form seams 25. However, it is alternatively possible to attach the ancillary panels to inner surface 30 of outer layer 24 after the complete formation thereof.

As used herein, the phrase “extending over,” particularly when used with reference to the extent that an outer layer of neoprene wetsuit material covers a body part, means that a vast majority of the respective body part is covered by the outer layer. Te body part may have a minor area covered by a layer of another material. For instance, along the inner surfaces of the arms, a patch of friction enhancing material may be used.

Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof. 

1. A wetsuit having a torso, arms and legs, said wetsuit comprising: an outer layer extending over said torso, said arms and said legs, said outer layer having a substantially uniform thickness throughout said torso, said arms and said legs; and a plurality of ancillary panels attached to said outer layer along an inner surface thereof.
 2. The wetsuit defined in claim 1 wherein said ancillary panels include a first plurality of panels disposed in a chest area of said torso, a second plurality of panels disposed in a back area of said torso, a third plurality of panels disposed in an abdominal region of said torso, a fourth plurality of panels disposed in each thigh region of said legs, and a fifth plurality of panels disposed in a calf region of each leg.
 3. The wetsuit defined in claim 1 wherein said outer layer has a thickness of approximately 2 mm throughout.
 4. The wetsuit defined in claim 1 wherein said ancillary layers each have a substantially uniform thickness of less than about 3 mm throughout.
 5. The wetsuit defined in claim 1 wherein said torso, said arms and said legs each have a longitudinal axis, said ancillary panels including: a first plurality of panels disposed in one of said torso, said arms and said legs, the panels of said first plurality of panels being spaced from one another along at least one elongate gal) extending substantially parallel to the respective longitudinal axis of said one of said torso, said arms and said legs; and a second plurality of panels disposed in another one of said torso, said arms and said legs, the panels of said second plurality of panels being spaced from one another along at least one elongate gap extending substantially parallel to the respective longitudinal axis of said another one of said torso, said arms and said legs.
 6. The wetsuit defined in claim 1 wherein said outer layer is made of a plurality of outer panels joined to one another along watertight seams, said outer panels each having said substantially uniform thickness.
 7. The wetsuit defined in claim 1 wherein said ancillary panels are made of a foam material.
 8. The wetsuit defined in claim 1 wherein said ancillary panels are bonded or adhesively adhered to said inner surface of said outer layer.
 9. The wetsuit defined in claim 1 wherein said ancillary panels are sewn along respective edges to said inner surface of said outer layer.
 10. The wetsuit defined in claim 1 wherein said outer layer extends over a vast majority of said torso, said arms and said legs.
 11. The wetsuit defined in claim 1 wherein said ancillary panels include a plurality of chest panels disposed on an anterior side of said torso, said anterior side of said torso having an axis extending from a neck region to a crotch region, said chest panels being spaced from one another along an elongate gap extending substantially parallel to said axis.
 12. The wetsuit defined in claim 1 wherein said ancillary panels include a plurality of abdominal panels disposed on an anterior side of said torso, said anterior side of said torso having an axis extending from a neck region to a crotch region, said abdominal panels being spaced from one another along an elongate gap extending substantially parallel to said axis.
 13. The wetsuit defined in claim 1 wherein said ancillary panels include a plurality of thigh panels disposed on one of said legs, said one of said legs having an axis extending from a crotch region of the wetsuit to a knee region, said thigh panels being spaced from one another along an elongate gap extending substantially parallel to said axis.
 14. The wetsuit defined in claim 1 wherein said ancillary panels include a plurality of calf panels disposed on one of said legs, said one of said legs having an axis extending from a knee region to an ankle region, said calf panels being spaced from one another along an elongate gap extending substantially parallel to said axis.
 15. A method of making a wetsuit comprising: cutting a plurality of outer panels from waterproof sheet material, said outer panels having the same substantially uniform thickness; attaching said outer panels to one another to form a continuous outer layer having a torso, arms and legs with said substantially uniform thickness throughout; cutting a plurality of ancillary panels from foam sheet material; and attaching said ancillary panels to said outer panels on an inner side thereof.
 16. The method defined in claim 15 wherein said outer layer has a thickness of approximately 2 mm throughout.
 17. The method defined in claim 15 wherein said ancillary layers each have a substantially uniform thickness of less than about 3 mm throughout.
 18. The method defined in claim 15 wherein said torso, said arms and said legs each have a longitudinal axis, the attaching of said ancillary panels including: attaching a first plurality of ancillary panels to outer panels of one of said torso, said arms and said legs so that the panels of said first plurality of ancillary panels are spaced from one another along at least one elongate gap extending substantially parallel to the respective longitudinal axis of said one of said torso, said arms and said legs; and attaching a second plurality of ancillary panels to outer panels of another one of said torso, said arms and said legs so that the panels of said second plurality of ancillary panels are spaced from one another along at least one elongate gap extending substantially parallel to the respective longitudinal axis of said another one of said torso, said arms and said legs.
 19. The method defined in claim 15 wherein the attaching of said ancillary panels includes bonding or adhesively adhering said ancillary panels to said outer panels.
 20. The method defined in claim 15 wherein the attaching of said ancillary panels includes sewing said ancillary panels along respective edges to said outer panels. 